CN116765758A - Welding and coating construction method for bridge structure - Google Patents
Welding and coating construction method for bridge structure Download PDFInfo
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- CN116765758A CN116765758A CN202310760333.3A CN202310760333A CN116765758A CN 116765758 A CN116765758 A CN 116765758A CN 202310760333 A CN202310760333 A CN 202310760333A CN 116765758 A CN116765758 A CN 116765758A
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- 238000003466 welding Methods 0.000 title claims abstract description 254
- 238000000576 coating method Methods 0.000 title claims abstract description 52
- 239000011248 coating agent Substances 0.000 title claims abstract description 46
- 238000010276 construction Methods 0.000 title claims abstract description 34
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 69
- 239000010959 steel Substances 0.000 claims abstract description 69
- 238000000034 method Methods 0.000 claims abstract description 60
- 239000003973 paint Substances 0.000 claims abstract description 37
- 230000008569 process Effects 0.000 claims abstract description 37
- 238000005488 sandblasting Methods 0.000 claims abstract description 34
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims abstract description 18
- 230000008439 repair process Effects 0.000 claims abstract description 17
- 238000007517 polishing process Methods 0.000 claims abstract description 10
- 238000005507 spraying Methods 0.000 claims description 26
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- 239000000428 dust Substances 0.000 claims description 6
- 229910052739 hydrogen Inorganic materials 0.000 claims description 6
- 239000001257 hydrogen Substances 0.000 claims description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 6
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/36—Successively applying liquids or other fluent materials, e.g. without intermediate treatment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/50—Multilayers
- B05D7/56—Three layers or more
- B05D7/58—No clear coat specified
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/18—Submerged-arc welding
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
- E01D19/00—Structural or constructional details of bridges
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
- E01D21/00—Methods or apparatus specially adapted for erecting or assembling bridges
- E01D21/06—Methods or apparatus specially adapted for erecting or assembling bridges by translational movement of the bridge or bridge sections
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Arc Welding In General (AREA)
Abstract
The invention discloses a welding and coating construction method of a bridge structure, and relates to the technical field of bridge construction. The method comprises the following steps: the steel arch shell is segmented, each quarter steel arch shell structure is divided into a plurality of pre-assembled modules, namely a first pre-assembled module, a second pre-assembled module, a third pre-assembled module, a fourth pre-assembled module, a fifth pre-assembled module and a sixth pre-assembled module, and each pre-assembled module is divided into a plurality of segmented components; welding the pre-assembled modules, and welding a plurality of segmented components, wherein an external surface weld seam surplus height control and repair polishing process and a low-voltage, high-flow-speed and high-current semi-automatic submerged arc welding process are adopted during welding; the pre-assembled module is coated, sand blasting and rust removal are firstly carried out, and then primer, intermediate paint and finish paint are sequentially sprayed. The welding shrinkage deformation amount is controlled, the size deviation is reduced, the welding quality is ensured, and the welding construction quality of the steel arch shell of the multi-curvature special-shaped curved surface box-shaped structure is ensured.
Description
Technical Field
The invention relates to the technical field of bridge construction, in particular to a welding and coating construction method of a bridge structure.
Background
The welding construction process and the coating construction process of the bridge steel arch shell are important key processes for the construction of the upper part of the bridge, and can directly influence the appearance quality and the attractive appearance of the bridge.
For steel shells of complex spatial multi-arch structures, the steel shells are mainly constructed as spatial three-dimensional curved surfaces, and the steel shells are inconsistent in shape. For the steel arch shell, if the conventional bridge welding operation is adopted, the problems of high welding randomness and limited rationality of component division are caused, and finally, the welding quality is caused to have larger quality defects. Secondly, rust removal work on steel products in the existing coating is often not in place, so that the whole coating quality is affected. Therefore, there is a need to provide a method of welding and coating construction for oversized, ultra-wide, and ultra-heavy complex steel dome members.
Disclosure of Invention
The invention mainly aims to provide a welding and coating construction method for a bridge structure, which aims to solve the problems in the prior art.
In order to solve the technical problems, the invention adopts the following technical scheme:
a welding and coating construction method of a bridge structure comprises the following steps:
s1, segment division is carried out on the steel arch shell
According to the position of a steel arch shell structure, the steel arch shell is divided into side girder end parts, side girder midspan, arch limbs, arch ribs and arch rib folding sections, the steel arch shell is arranged in a quarter mirror symmetry structure by taking the center of the arch rib folding section as an axis, each quarter steel arch shell structure is divided into a plurality of pre-assembled modules, namely a first pre-assembled module, a second pre-assembled module, a third pre-assembled module, a fourth pre-assembled module, a fifth pre-assembled module and a sixth pre-assembled module, wherein the first pre-assembled module is positioned at the side girder end parts, the second pre-assembled module, the third pre-assembled module, the fourth pre-assembled module and the fifth pre-assembled module are positioned at the arch ribs and the side girder midspan, the sixth pre-assembled module is positioned at the arch rib folding section, and each pre-assembled module is divided into a plurality of sectional members;
s2, welding the pre-assembled module
Welding the processed arc-shaped plate, the rolled plate, the double-curved wall plate and the stiffening rib into segmented components corresponding to each segment of the steel arch shell, and welding the segmented components to form a first pre-assembled module, a second pre-assembled module, a third pre-assembled module, a fourth pre-assembled module, a fifth pre-assembled module and a sixth pre-assembled module, wherein an external surface weld seam surplus height control and repair polishing process and a low-voltage, high-flow-rate and high-current semiautomatic submerged arc welding process are adopted during welding;
s3, coating the preassembled module
And (3) carrying out sand blasting and rust removal on the welded preassembled module, removing dust and sundries on the surface of the metal coating after sand blasting, spraying primer after sand blasting, and sequentially spraying intermediate paint and finish paint after the primer is completely dried.
Further, the end part of the side girder is divided into 32 segmented components in total, the midspan of the side girder is divided into 52 segmented components in total, the arch is divided into 48 segmented components in total, the arch rib is divided into 20 segmented components in total, and the closure section of the arch rib is divided into 3 segmented components in total.
Furthermore, the arc-shaped plate, the coiled plate, the double-curved plate and the stiffening rib in the S2 adopt parts with blanking errors within 3mm, the forming dimensional errors of the parts are controlled within 5mm, the butt joint gaps of the parts are uniform, and no offset is caused; in the external surface weld seam surplus height control and repair polishing process, a semi-automatic submerged arc welding process is adopted for butt welding, an angle grinder is adopted for polishing the welding, and the weld seam surplus height is controlled within 0.4 mm.
Further, CO is adopted in the low-voltage, high-flow-rate and high-current semi-automatic submerged arc welding process 2 Gas shielded welding, CO 2 The gas purity is not less than 99.5%, a low-hydrogen solid welding wire with the diffusion hydrogen content less than 5ml/100g is selected, the voltage is 32-38V, the current is 500-600A, and the flow rate is 12-20L/min.
Furthermore, impulse intermittent welding is adopted for the stiffening ribs at the complex parts.
Further, in step S2, preparation before welding is required, and the operation process is as follows:
(1) Drying the welding rod and the welding flux, and removing oil, rust, primer and water on the surfaces of the joint groove and the accessories thereof;
(2) Preheating each welding piece according to the preheating temperature specified by the welding process, wherein the preheating range is generally more than 100mm on each side of the welding line, and measuring the temperature within the range of 30-50 mm from the welding line;
(3) After the positions of the welding pieces are determined, fixing is carried out by using a positioning welding, for a welding line which is welded on two sides and needs back chipping, the positioning welding is arranged on the back, for a sectional component with symmetrical shape, the positioning welding is arranged symmetrically, the positioning welding line is 30mm or more from the end part of the designed welding line, the length of the positioning welding line is 50-100 mm, the interval of the positioning welding line is 400-600 mm, and the size of a welding leg of the positioning welding line is not greater than 1/2 of the size of the designed welding leg.
Further, the semi-automatic submerged arc welding operation process is as follows:
(1) The end part of the welding line is required to be welded with an arc striking plate and a leading-out plate, the material and the bevel of the arc striking plate are the same as those of a welding piece, and the arc striking and extinguishing is more than 80mm outside the formal welding line;
(2) When welding, arc breaking is not needed, if arc breaking occurs, the arc stopping position must be planed into a slope not steeper than 1:5, and the arc stopping position is lapped for 50mm, then welding is continued, and the lapped part is polished uniformly and smoothly after welding;
(3) Welding according to the welding position, the welding process parameters, the welding sequence and the welding direction specified in the welding process, wherein the tightly-propped stiffening rib plate starts from the tightly-propped end to the other end;
(4) In the multi-layer welding process, each time the welding is completed, slag is cleaned, welding seams and nearby base materials are cleaned, and then the next welding is performed.
Further, weld grinding and repairing are needed after welding, and the operation process is as follows:
(1) After welding, cutting off the leading plates at two ends by adopting a flame cutting or gas cutting method, knocking away slag after the welding line is cooled slightly, cleaning slag and splashes, and smoothly polishing all the welding lines;
(2) The welding seam with the welding leg size, welding wave or residual height exceeding the upper limit value specified in the specification is trimmed and smoothed, and the seam is smaller than 1mm and out of tolerance;
(3) When the seam undercut exceeds 1mm or the welding leg size is insufficient, performing repair welding by adopting manual arc welding;
(4) Removing welding defects by adopting a carbon arc gouging method, planing a groove which is beneficial to repair welding when the defects are removed, and grinding oxide skin on the surface of the groove by using a grinding wheel to expose metallic luster;
(5) The removal length of the weld cracks extends 50mm from each crack end.
Further, the operation procedure of sand blasting and rust removal in step S3 is as follows:
(1) Starting the air compressor, and adjusting the pressure to 5-7kg/cm 2 ；
(2) Loading the dried abrasive into a sand blasting machine to ensure that an oil-water separator on the sand blasting machine works normally;
(3) Putting steel materials in order, and starting a sand blasting machine to start sand blasting operation;
(4) And after the sand blasting operation is finished, dust removal, oil removal and cleaning are carried out on the surface of the steel.
Further, the spraying operation in step S3 is as follows:
(1) Each side of the spot welding joint is left to be 50mm wide and is not coated, the spot welding joint is protected, and coating can be performed after spot welding is finished;
(2) When coating is carried out, the thickness of a wet film is measured by a wet film thickness gauge so as to control the thickness of a paint film;
(3) Spraying primer within 4 hours after sand blasting, checking the thickness of a paint film after finishing the primer, and brushing intermediate paint after the primer is completely dried at intervals of 6-8 hours;
(4) The large-area spraying is performed by adopting high-pressure airless spraying, the distance between the spray gun nozzle and the surface of the steel plate is 300-500 mm, the spraying is performed under the conditions that the air humidity is less than 80% and the surface temperature of the steel plate is higher than the air dew point by 3 ℃, and the ambient temperature is 5-38 ℃;
(5) The final finish paint is coated after the steel beam is folded, the paint surface is prevented from being polluted by construction in other working procedures, and damaged coatings in the transportation and installation processes are repaired before the final finish paint is constructed;
(6) And (5) coating the parts which are not sprayed by adopting a brushing method.
Compared with the prior art, the invention has the following beneficial effects:
dividing the end part of a side longitudinal beam, the midspan of the side longitudinal beam, the combined section of an arched beam, an arched rib, an arched limb and a folding section of the steel arched shell into a plurality of segmented components, respectively welding the segmented components into a first pre-assembled module, a second pre-assembled module, a third pre-assembled module, a fourth pre-assembled module, a fifth pre-assembled module and a sixth pre-assembled module, then coating, and finally transporting the segmented components to the site for segmented hoisting to complete the installation of the bridge steel arched shell, wherein the welding shrinkage deformation is controlled in the mode, and the size deviation is reduced; the weld seam surplus height is less than 0.4mm by adopting an external surface weld seam surplus height control and repair polishing process and a low-voltage, high-flow-speed and high-current semi-automatic submerged arc welding process, so that the welding quality is ensured; for stiffening ribs at complex parts, a pulse intermittent welding method is adopted, so that the temperature field change and the steel thermal deformation caused by welding are reduced to the greatest extent; finally, the welding construction quality of the steel arch shell of the multi-curvature special-shaped curved surface box-shaped structure is effectively ensured;
the steel is subjected to sand blasting and rust removal, so that oxide scales and rust can be removed, certain roughness can be formed on the metal surface, the binding force between the coating and the metal surface is increased, and the subsequent spraying quality is ensured.
Drawings
FIG. 1 is a schematic view of the overall structure of the steel shell of the present invention.
Fig. 2 is an elevation view of a steel shell of the present invention.
Fig. 3 is a schematic view of a quarter steel shell construction according to the present invention.
Fig. 4 is a schematic structural view of a first preassembled module according to the present invention.
Fig. 5 is a schematic structural diagram of a second preassembled module according to the present invention.
Fig. 6 is a schematic structural diagram of a third preassembled module according to the present invention.
Fig. 7 is a schematic structural diagram of a fourth preassembled module according to the present invention.
Fig. 8 is a schematic structural view of a fifth preassembled module according to the present invention.
Fig. 9 is a schematic structural view of a sixth preassembled module according to the present invention.
Fig. 10 is a flow chart of the coating process of the present invention.
The device comprises a 1-side longitudinal beam end part, a 2-side longitudinal beam midspan, a 3-arch limb, a 4-arch rib and a 5-arch rib folding section.
Detailed Description
The technical scheme of the invention is further described below through the attached drawings and the embodiments.
A welding and coating construction method of a bridge structure comprises the following steps:
s1, segment division is carried out on the steel arch shell
According to the structure position of the steel arch shell, the steel arch shell is divided into a side longitudinal beam end part 1, a side longitudinal beam midspan 2, an arch limb 3, an arch rib 4 and an arch rib folding section 5, the steel arch shell takes the center of the arch rib folding section as an axis to be arranged into a quarter mirror symmetry structure, each quarter steel arch shell structure is divided into a plurality of pre-assembled modules, namely a first pre-assembled module, a second pre-assembled module, a third pre-assembled module, a fourth pre-assembled module, a fifth pre-assembled module and a sixth pre-assembled module, the first pre-assembled module is positioned at the side longitudinal beam end part 1, the second pre-assembled module, the third pre-assembled module, the fourth pre-assembled module and the fifth pre-assembled module are positioned at the arch rib 3 and the side longitudinal beam midspan 2, and the sixth pre-assembled module is positioned at the arch rib folding section 5, and each pre-assembled module is divided into a plurality of sectional members;
s2, welding the pre-assembled module
Welding the processed arc-shaped plate, the rolled plate, the double-curved wall plate and the stiffening rib into segmented components corresponding to each segment of the steel arch shell, and welding the segmented components to form a first pre-assembled module, a second pre-assembled module, a third pre-assembled module, a fourth pre-assembled module, a fifth pre-assembled module and a sixth pre-assembled module, wherein an external surface weld seam surplus height control and repair polishing process and a low-voltage, high-flow-rate and high-current semiautomatic submerged arc welding process are adopted during welding;
s3, coating the preassembled module
And (3) carrying out sand blasting and rust removal on the welded preassembled module, removing dust and sundries on the surface of the metal coating after sand blasting, spraying primer after sand blasting, and sequentially spraying intermediate paint and finish paint after the primer is completely dried.
In the embodiment, the steel arch shell is of a complex space multi-arch structure, the overall design height of the steel arch shell is 30m, 7.5m of the steel arch shell is positioned on two sides of the main bridge, 22.2m of the steel arch shell is positioned above the upper deck, the section thickness of the arch rib is 800mm, the width of the arch rib is from 0.8m to 6m, and the section size is larger. Wherein, the range of 30.59m of the end part of the side girder is welded with the bridge deck system of the upper layer of the main bridge; the middle part of the side longitudinal beam is welded and connected with the bridge deck system of the lower layer of the main bridge; the arch limb adopts a steel box structure, the thickness of the steel box is 8-14 mm, the top side plate, the web plate and the inner side plate are all provided with plate type stiffening ribs, the arc chamfer angle of the arch limb adopts an 8mm outsourcing steel plate, and the steel structure arch adopts Q345D steel.
Specifically, the end part of the side longitudinal beam is divided into 32 segmented components in total, the midspan of the side longitudinal beam is divided into 52 segmented components in total, the arch limb is divided into 48 segmented components in total, the arch rib is divided into 20 segmented components in total, the closure section of the arch rib is divided into 3 segmented components in total, the total bridge is divided into 155 segmented components in total, the four areas of ABCD are divided, and the segmented components of each area are prefixed with respective area codes.
Table 1 list of steel arch shell segment members
Preferably, the arc-shaped plate, the coiled plate, the double-curved plate and the stiffening rib in the S2 adopt parts with blanking errors within 3mm, the forming dimensional errors of the parts are controlled within 5mm, the butt joint gaps of the parts are uniform, and no offset is caused; in the external surface weld seam surplus height control and repair polishing process, a semi-automatic submerged arc welding process is adopted for butt welding, an angle grinder is adopted for polishing the welding, and the weld seam surplus height is controlled within 0.4 mm.
In the embodiment, the following guarantee measures are provided for the process of controlling, repairing and polishing the weld seam surplus height of the outer surface:
(1) High assembly accuracy
The numerical control plasma accurate blanking is performed, the blanking error of the part is controlled to be within 3mm, and a semi-automatic cutting machine is adopted as far as possible for the cutting of the plate; the forming dimension error of the coiled plate and the pressing plate control part is 5mm; and the total station is used for measurement, the three-dimensional jig frame is assembled, the jig frame size control error is 3mm, the butt joint is controlled smoothly, the butt joint gap is uniform in size, and the staggered edges are avoided.
(2) Semi-automatic submerged arc welding
The butt welding seam adopts a semi-automatic submerged arc welding process, so that the quality of the welding seam is ensured, the welding seam is well formed, and the surplus height of the welding seam is controlled.
(3) Polishing process
And the equipment is adopted for polishing, so that manual polishing is reduced, and the surplus height of the weld seam is controlled within 0.4 mm.
Preferably, CO is adopted in the low-voltage, high-flow-rate and high-current semiautomatic submerged arc welding process 2 Gas shielded welding, CO 2 The gas purity is not less than 99.5%, a low-hydrogen solid welding wire with the diffusion hydrogen content less than 5ml/100g is selected, the voltage is 32-38V, the current is 500-600A, and the flow rate is 12-20L/min.
In this embodiment, the following measures are taken to reduce the solder trace:
(1) Welding process
Different welding methods will produce different temperature fields and different thermal deformations are formed. Generally, the automatic welding is more concentrated in heating than the manual welding, and has a narrower heated area and less deformation. CO 2 The gas shielded welding wire is thin, the current density is high, the heating is concentrated, and the deformation is small.
(2) Welding parameters
I.e. welding current, arc voltage and welding speed. The larger the line energy, the larger the welding deformation, which increases with an increase in welding current and arc voltage and decreases with an increase in welding speed. Among the 3 parameters, the arc voltage acts significantly, so that the automatic welding deformation of low voltage, high speed and high current density is small.
(3) Number of welds and cross-section size
The greater the number of welds, the greater the cross-sectional dimension and the greater the weld distortion, and therefore the need to reduce stiffener fillet height.
(4) Construction method
The thermal deformation generated by the continuous welding and the intermittent welding is different from each other. The continuous welding deformation is usually larger, and the intermittent welding deformation is minimum. Intermittent welding is adopted as far as possible for stiffening ribs at complex parts.
Preferably, in step S2, a preparation before welding is required, and the operation procedure is as follows:
(1) Drying the welding rod and the welding flux, and removing oil, rust, primer and water on the surfaces of the joint groove and the accessories thereof;
(2) Preheating each welding piece according to the preheating temperature specified by the welding process, wherein the preheating range is generally more than 100mm on each side of the welding line, and measuring the temperature within the range of 30-50 mm from the welding line;
(3) After the positions of the welding pieces are determined, fixing is carried out by using a positioning welding, for a welding line which is welded on two sides and needs back chipping, the positioning welding is arranged on the back, for a sectional component with symmetrical shape, the positioning welding is arranged symmetrically, the positioning welding line is 30mm or more from the end part of the designed welding line, the length of the positioning welding line is 50-100 mm, the interval of the positioning welding line is 400-600 mm, and the size of a welding leg of the positioning welding line is not greater than 1/2 of the size of the designed welding leg.
Preferably, the semi-automatic submerged arc welding is operated as follows:
(1) The end part of the welding line is required to be welded with an arc striking plate and a leading-out plate, the material and the bevel of the arc striking plate are the same as those of a welding piece, and the arc striking and extinguishing is more than 80mm outside the formal welding line;
(2) When welding, arc breaking is not needed, if arc breaking occurs, the arc stopping position must be planed into a slope not steeper than 1:5, and the arc stopping position is lapped for 50mm, then welding is continued, and the lapped part is polished uniformly and smoothly after welding;
(3) Welding according to the welding position, the welding process parameters, the welding sequence and the welding direction specified in the welding process, wherein the tightly-propped stiffening rib plate starts from the tightly-propped end to the other end;
(4) In the multi-layer welding process, each time the welding is completed, slag is cleaned, welding seams and nearby base materials are cleaned, and then the next welding is performed.
Preferably, the welding seam is required to be ground and repaired after welding, and the operation process is as follows:
(1) After welding, cutting off the leading plates at two ends by adopting a flame cutting or gas cutting method, knocking away slag after the welding line is cooled slightly, cleaning slag and splashes, and smoothly polishing all the welding lines;
(2) The welding seam with the welding leg size, welding wave or residual height exceeding the upper limit value specified in the specification is trimmed and smoothed, and the seam is smaller than 1mm and out of tolerance;
(3) When the seam undercut exceeds 1mm or the welding leg size is insufficient, performing repair welding by adopting manual arc welding;
(4) Removing welding defects by adopting a carbon arc gouging method, planing a groove which is beneficial to repair welding when the defects are removed, and grinding oxide skin on the surface of the groove by using a grinding wheel to expose metallic luster;
(5) The removal length of the weld cracks extends 50mm from each crack end.
Preferably, the operation procedure of sand blasting and rust removal in step S3 is as follows:
(1) Starting the air compressor, and adjusting the pressure to 5-7kg/cm 2 ；
(2) Loading the dried abrasive into a sand blasting machine to ensure that an oil-water separator on the sand blasting machine works normally;
(3) Putting steel materials in order, and starting a sand blasting machine to start sand blasting operation;
(4) And after the sand blasting operation is finished, dust removal, oil removal and cleaning are carried out on the surface of the steel.
The steel is subjected to sand blasting and rust removal, oxide scale and rust can be removed, certain roughness can be formed on the metal surface, the binding force between the coating and the metal surface is increased, the subsequent spraying quality is ensured, the influence on the adhesive force service life of the coating is avoided, and the economic loss is caused. Because of the fluidity of construction work, the current general construction adopts dry sand blasting to remove rust, uses copper sand or steel shot and the like as abrasive materials, uses 5-7kg/cm 2 The compressed air with pressure, which is dry and clean, drives the abrasive to spray the metal surface, so that oxide skin and rust on the steel surface can be removed.
Preferably, the spraying operation in step S3 is as follows:
(1) Each side of the spot welding joint is left to be 50mm wide and is not coated, the spot welding joint is protected, and coating can be performed after spot welding is finished;
(2) When coating is carried out, the thickness of a wet film is measured by a wet film thickness gauge so as to control the thickness of a paint film;
(3) Spraying primer within 4 hours after sand blasting, checking the thickness of a paint film after finishing the primer, and brushing intermediate paint after the primer is completely dried at intervals of 6-8 hours;
(4) The large-area spraying is performed by adopting high-pressure airless spraying, the distance between the spray gun nozzle and the surface of the steel plate is 300-500 mm, the spraying is performed under the conditions that the air humidity is less than 80% and the surface temperature of the steel plate is higher than the air dew point by 3 ℃, and the ambient temperature is 5-38 ℃;
(5) The final finish paint is coated after the steel beam is folded, the paint surface is prevented from being polluted by construction in other working procedures, and damaged coatings in the transportation and installation processes are repaired before the final finish paint is constructed;
(6) And (5) coating the parts which are not sprayed by adopting a brushing method.
In this embodiment, the technical assurance measures of the coating quality are as follows:
(1) The rust removal and coating operation should be carried out in an independent indoor workshop to ensure the coating quality and prevent environmental pollution, the inorganic zinc-rich paint, polyurethane paint and fluorocarbon finish paint are not allowed to be constructed below 5 ℃, the epoxy zinc-rich paint and epoxy cloud iron intermediate paint are not allowed to be constructed below 10 ℃, the construction environment temperature is not higher than 38 ℃, and the steel surface temperature is higher than the dew point 3 ℃;
(2) Construction is not allowed in rainy days, foggy days or sand-blown occasions with the relative humidity of more than 80%;
(3) After the upper coating is dried, the paint can be coated, the longest exposure time of the primer and the intermediate paint does not exceed the related technical requirements of material suppliers, and when the maximum repainting interval is exceeded, the roughening treatment is required according to the specification.
(4) The surface stress of the paint coating is smoothed and flattened, and the finish paint is smooth and beautiful and has uniform color; the coating process can not have pinholes, obvious sagging, skin wrinkling, missing coating and other defects; if the inspection finds that the defects are to be immediately repaired and coated;
(5) In order to ensure the film thickness, the parts such as free edges and the like which are difficult to coat are brushed for one time and two times by using a brush before high-pressure airless spraying;
(6) Finally, the painting work is carried out after finishing various decoration works and correcting various defects, the cleaning work is carefully carried out before painting, shielding protection on related parts is needed to be paid attention to during spraying, concentrated color mixing is needed, and film forming is carried out through one-time spraying, so that the appearance quality of a clean and attractive coating is obtained;
(7) The damaged parts of various coatings need to be repaired one by one according to the regulation, and the coating in the range of 25-30% around the damaged area before repair is polished to a gradient so as to be convenient for repair smoothness;
(8) The paint should be stirred fully and evenly for construction, and an electric or pneumatic stirring device is adopted. For the bi-component or multi-component paint, the components are firstly and respectively stirred uniformly, and then are prepared according to the proportion and stirred uniformly.
According to the method, the end part of the side longitudinal beam, the midspan of the side longitudinal beam, the combined section of the arched beam, the arched rib, the arched limb and the folding section of the steel arched shell are divided into a plurality of segmented components, the segmented components are welded into a first pre-assembled module, a second pre-assembled module, a third pre-assembled module, a fourth pre-assembled module, a fifth pre-assembled module and a sixth pre-assembled module respectively, then coating is carried out, and finally the segmented components are transported to the site for segmented hoisting, so that the installation of the bridge steel arched shell is completed, and the welding shrinkage deformation is controlled and the size deviation is reduced in the mode; the weld seam surplus height is less than 0.4mm by adopting an external surface weld seam surplus height control and repair polishing process and a low-voltage, high-flow-speed and high-current semi-automatic submerged arc welding process, so that the welding quality is ensured; for stiffening ribs at complex parts, a pulse intermittent welding method is adopted, so that the temperature field change and the steel thermal deformation caused by welding are reduced to the greatest extent; and finally, the welding construction quality of the steel arch shell of the multi-curvature special-shaped curved surface box-shaped structure is effectively ensured.
The foregoing description is only a preferred embodiment of the present invention, and is not intended to limit the technical scope of the present invention, so any minor modifications, equivalent changes and modifications made to the above embodiments according to the technical principles of the present invention still fall within the scope of the technical solutions of the present invention.
Claims (10)
1. The welding and coating construction method of the bridge structure is characterized by comprising the following steps of:
s1, segment division is carried out on the steel arch shell
According to the position of a steel arch shell structure, the steel arch shell is divided into side girder end parts, side girder midspan, arch limbs, arch ribs and arch rib folding sections, the steel arch shell is arranged in a quarter mirror symmetry structure by taking the center of the arch rib folding section as an axis, each quarter steel arch shell structure is divided into a plurality of pre-assembled modules, namely a first pre-assembled module, a second pre-assembled module, a third pre-assembled module, a fourth pre-assembled module, a fifth pre-assembled module and a sixth pre-assembled module, wherein the first pre-assembled module is positioned at the side girder end parts, the second pre-assembled module, the third pre-assembled module, the fourth pre-assembled module and the fifth pre-assembled module are positioned at the arch ribs and the side girder midspan, the sixth pre-assembled module is positioned at the arch rib folding section, and each pre-assembled module is divided into a plurality of sectional members;
s2, welding the pre-assembled module
Welding the processed arc-shaped plate, the rolled plate, the double-curved wall plate and the stiffening rib into segmented components corresponding to each segment of the steel arch shell, and welding the segmented components to form a first pre-assembled module, a second pre-assembled module, a third pre-assembled module, a fourth pre-assembled module, a fifth pre-assembled module and a sixth pre-assembled module, wherein an external surface weld seam surplus height control and repair polishing process and a low-voltage, high-flow-rate and high-current semiautomatic submerged arc welding process are adopted during welding;
s3, coating the preassembled module
And (3) carrying out sand blasting and rust removal on the welded preassembled module, removing dust and sundries on the surface of the metal coating after sand blasting, spraying primer after sand blasting, and sequentially spraying intermediate paint and finish paint after the primer is completely dried.
2. The welding and coating construction method for a bridge structure according to claim 1, wherein the end of the side frame is divided into 32 segmented members in total, the mid-span of the side frame is divided into 52 segmented members in total, the arch is divided into 48 segmented members in total, the arch rib is divided into 20 segmented members in total, and the arch rib folding section is divided into 3 segmented members in total.
3. The welding and coating construction method of a bridge structure according to claim 1, wherein the arc-shaped plate, the coiled plate, the double-curved plate and the stiffening rib in the S2 adopt parts with blanking errors within 3mm, the forming dimensional errors of the parts are controlled within 5mm, the butt joint gaps of the parts are uniform in size, and no offset is caused; in the external surface weld seam surplus height control and repair polishing process, a semi-automatic submerged arc welding process is adopted for butt welding, an angle grinder is adopted for polishing the welding, and the weld seam surplus height is controlled within 0.4 mm.
4. A method for welding and coating a bridge structure according to claim 1 or 3, wherein the low-voltage, high-flow and high-current semi-automatic submerged arc welding process adopts CO 2 Gas shielded welding, CO 2 The gas purity is not less than 99.5%, a low-hydrogen solid welding wire with the diffusion hydrogen content less than 5ml/100g is selected, the voltage is 32-38V, the current is 500-600A, and the flow rate is 12-20L/min.
5. The method of welding and painting a bridge structure according to claim 4, wherein the intermittent welding is performed by pulse type on the stiffening ribs at the complex portions.
6. The welding and painting construction method for a bridge structure according to claim 4, wherein in step S2, preparation before welding is required, and the operation process is as follows:
(1) Drying the welding rod and the welding flux, and removing oil, rust, primer and water on the surfaces of the joint groove and the accessories thereof;
(2) Preheating each welding piece according to the preheating temperature specified by the welding process, wherein the preheating range is generally more than 100mm on each side of the welding line, and measuring the temperature within the range of 30-50 mm from the welding line;
(3) After the positions of the welding pieces are determined, fixing is carried out by using a positioning welding, for a welding line which is welded on two sides and needs back chipping, the positioning welding is arranged on the back, for a sectional component with symmetrical shape, the positioning welding is arranged symmetrically, the positioning welding line is 30mm or more from the end part of the designed welding line, the length of the positioning welding line is 50-100 mm, the interval of the positioning welding line is 400-600 mm, and the size of a welding leg of the positioning welding line is not greater than 1/2 of the size of the designed welding leg.
7. The welding and coating construction method for bridge structures according to claim 5, wherein the semi-automatic submerged arc welding is operated as follows:
(1) The end part of the welding line is required to be welded with an arc striking plate and a leading-out plate, the material and the bevel of the arc striking plate are the same as those of a welding piece, and the arc striking and extinguishing is more than 80mm outside the formal welding line;
(2) When welding, arc breaking is not needed, if arc breaking occurs, the arc stopping position must be planed into a slope not steeper than 1:5, and the arc stopping position is lapped for 50mm, then welding is continued, and the lapped part is polished uniformly and smoothly after welding;
(3) Welding according to the welding position, the welding process parameters, the welding sequence and the welding direction specified in the welding process, wherein the tightly-propped stiffening rib plate starts from the tightly-propped end to the other end;
(4) In the multi-layer welding process, each time the welding is completed, slag is cleaned, welding seams and nearby base materials are cleaned, and then the next welding is performed.
8. The welding and coating construction method of a bridge structure according to claim 7, wherein the welding is followed by a weld grinding and repairing process comprising the steps of:
(1) After welding, cutting off the leading plates at two ends by adopting a flame cutting or gas cutting method, knocking away slag after the welding line is cooled slightly, cleaning slag and splashes, and smoothly polishing all the welding lines;
(2) The welding seam with the welding leg size, welding wave or residual height exceeding the upper limit value specified in the specification is trimmed and smoothed, and the seam is smaller than 1mm and out of tolerance;
(3) When the seam undercut exceeds 1mm or the welding leg size is insufficient, performing repair welding by adopting manual arc welding;
(4) Removing welding defects by adopting a carbon arc gouging method, planing a groove which is beneficial to repair welding when the defects are removed, and grinding oxide skin on the surface of the groove by using a grinding wheel to expose metallic luster;
(5) The removal length of the weld cracks extends 50mm from each crack end.
9. The welding and coating construction method of a bridge structure according to claim 1, wherein the operation process of sand blasting and rust removal in step S3 is as follows:
(1) Starting the air compressor, and adjusting the pressure to 5-7kg/cm 2 ；
(2) Loading the dried abrasive into a sand blasting machine to ensure that an oil-water separator on the sand blasting machine works normally;
(3) Putting steel materials in order, and starting a sand blasting machine to start sand blasting operation;
(4) And after the sand blasting operation is finished, dust removal, oil removal and cleaning are carried out on the surface of the steel.
10. The welding and painting construction method for a bridge structure according to claim 9, wherein the spraying operation in step S3 is as follows:
(1) Each side of the spot welding joint is left to be 50mm wide and is not coated, the spot welding joint is protected, and coating can be performed after spot welding is finished;
(2) When coating is carried out, the thickness of a wet film is measured by a wet film thickness gauge so as to control the thickness of a paint film;
(3) Spraying primer within 4 hours after sand blasting, checking the thickness of a paint film after finishing the primer, and brushing intermediate paint after the primer is completely dried at intervals of 6-8 hours;
(4) The large-area spraying is performed by adopting high-pressure airless spraying, the distance between the spray gun nozzle and the surface of the steel plate is 300-500 mm, the spraying is performed under the conditions that the air humidity is less than 80% and the surface temperature of the steel plate is higher than the air dew point by 3 ℃, and the ambient temperature is 5-38 ℃;
(5) The final finish paint is coated after the steel beam is folded, the paint surface is prevented from being polluted by construction in other working procedures, and damaged coatings in the transportation and installation processes are repaired before the final finish paint is constructed;
(6) And (5) coating the parts which are not sprayed by adopting a brushing method.
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| CN202310760333.3A CN116765758A (en) | 2023-06-26 | 2023-06-26 | Welding and coating construction method for bridge structure |
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